Optoma Pico PK301+ User manual

SERVICE MANUAL
Prepared: Cherry Check:Amy Approved: Alick
Date Revise Version Description
2010.04.15 V1.0 Initial Issue
2010.08.04 V2.0 Add “System reset“ & change burn-in test in Chapter 4 Add an action to show ”System Upgrade” & FW
version checking in Chapter 5
2011.08.23 V3.0 Add PK320
2012.10.19 V4.0 Add PK301 PLUS
PK-301/PK320/PK301 PLUS
Copyright Oct 2012. All Rights Reserved

Condential
PK-301/PK320/PK301 PLUS I
Preface
This manual is applied to PK-301/PK320/PK301 PLUS projection system. The manual
gives you a brief description of basic technical information to help in service and maintain
the product.Your customers will appreciate the quick response time when you immediately
identify problems that occur with our products. We expect your customers will appreciate
the service that you offer them.
This manual is for technicians and people who have an electronic background. Please
send the product back to the distributor for repairing and do not attempt to do anything that
is complex or is not mentioned in the troubleshooting.
Note: The information found in this manual is subject to change without prior notice. Any
subsequent changes made to the data herein will be incorporated in future edition.
PK-301/PK320/PK301 PLUS Service Manual
Copyright Oct 2012
All Rights Reserved
Manual Version 4.0

Condential II
PK-301/PK320/PK301 PLUS
Parts PK-301 PK301 PLUS PK320
Top Cover
Module 75.8CU05G001 75.8MH01G001
Main Board 80.8CU01G002 80.8RF01G001 80.8MH01G001
Keypad 80.8CU03G001 80.8MH03G001
Key Button 51.8CU16G101 51.8MH01G001
Focus Ring 51.8CU14G001 51.8CU14G011
Engine 70.8CU02GR01 70.8MH06GR01
PK-301/PK320/PK301 PLUS Comparison List

Condential
PK-301/PK320/PK301 PLUS III
Table of Content
Chapter 1 Introduction
Highlight 1-1
Compatible Mode 1-2
Chapter 2 Disassembly Process
Equipment Needed & Product Overview 2-1
Disassemble Battery Cover Module 2-2
Disassemble Bottom Cover Module 2-2
Disassemble Main Board Module and Rear Cover Module 2-3
Disassemble Fan Module and Engine Module 2-5
Disassemble Keypad Module 2-6
Disassemble the Bottom Cover 2-7
Chapter 3 Troubleshooting
Equipment Needed 3-1
Main Procedure 3-2
Power Troubleshooting 3-3
Image Performance Troubleshooting 3-4
Audio Troubleshooting 3-7
Chapter 4 Function Test & Alignment Procedure
Test Equipment Needed 4-1
Service Mode 4-1
System Reset 4-1
Test Condition 4-2
Test Inspection Procedure 4-3
Power and Led indicator 4-3

Condential
PK-301/PK320/PK301 PLUS IV
PC Mode 4-4
Video Performance 4-6
SD Card Test 4-7
Optical Performance Measure 4-7
Others 4-9
Chapter 5 Firmware Upgrade
Equipment Needed 5-1
Firmware Upgrade Procedure 5-2
Chapter 6 EDID Upgrade
EDID introduction 6-1
Equipment needed 6-2
Setup procedure 6-3
EDID Key-In Procedure(VGA & HDMI Interface) 6-3
Appendix A
Exploded Image I
Appendix B
   SerialNumberSystemDenition     XII
   PCBACodeDenition      XIII

 1-1
Chapter 1
Introduction
PK-301/PK320/PK301 PLUS
No  
1
       

      

2    
3 
      
       

   ""
7         

8



9
       
 

10                

11 

            





12     
13        
 






1-1 Highlight

 1-2
PK-301/PK320/PK301 PLUS
1-2 Compatible Mode
Computer compatibility
Compatibility  V-Sync[Hz]

 
 
 
 
 
 

 
 
720P 
 

 
 
720P 
 

Condential 2-1
Chapter 2
Disassembly Process
2-1 Equipment Needed & Product Overview
1. Screw Bit (+): No.00
2. Hex Sleeves 5mm
3. PK301/PK320/PK301 PLUS unit
* Before you start: This process is protective level II. Operators should wear electrostatic chains.
* Note : - If you need to replace the main board, you have to record the lamp usage hour.
- The disasssemble procedure for PK301/PK320/PK301 PLUS are the same ,we take
PK-301 as an example here.
PK-301/PK320/PK301 PLUS

Condential 2-2
2-3 Disassemble Top Cover
Module
1. Unscrew 5 screws from the Bottom
Cover (as red circle).
2-2 Disassemble Battery
Cover Module
1. Disassemble the Battery Cover Module
(as red arrow directs).
2. Remove the Battery.
PK-301/PK320/PK301 PLUS

Condential 2-3
2. Unplug the keypad cable.
3. Disassemble Top Cover Module
Note: - There are 3 tenons (as blue circle)
on the top cover,when disassembling
it, you must be carefull so as not to
damage the top cover.
2-4 Disassemble Keypad
Module
1. Tear off the 3M tape and unplug the key
pad cable.
2. Unscrew 4 screws(as red circle)
3. Take out the key pad board and the
key button.
PK-301/PK320/PK301 PLUS

Condential 2-4
2-5 Disassemble Main Board
Module and Rear Cover
Module
1. Unscrew 5 screws(as red circle).
2. Unplug 3 cables(as yellow circle).
3. Disassemble the Rear Cover(as yellow
arrow)
4. Unscrew 2 screws,separate the Rear
Cover and Main Board.
2-6 Disassemble Fan
Module and Engine
Module
1. Unscrew 3 screws as yellow circle.Then
take out the fan module.
AB
PK-301/PK320/PK301 PLUS

Condential 2-5
5. Unscrew 8 screws(as red circle) and
disassemble 3 heatsinks.
2. Unscrew 5 screws as red circle.
3. Unscrew 3 screws on the focus(as yellow
square).
4. Pull out the focus ring.
Note: When assembling the focus ring,you
should screw the 3 screws rst,then push in
the focus ring.
PK-301/PK320/PK301 PLUS

Condential 2-6
2-7 Disassemble the Bottom
cover
1. Unscrew 2 screws (as red circle).
2. Take out the power cord.
3. Disassemble complete.
6.Unscrew 2 screws and disassemble the
FPC cable.(As red circle)
7.Unscrew 2 screws, disassemble the
engine holder and DMD chip.(As yellow
circle)
PK-301/PK320/PK301 PLUS

Condential 3-1
Chapter 3
Troubleshooting
1.Projector
2.DVD player
3.Power adaptor with AC Plug
4.VGA Cable,USB Male Cable,AV Cable
5.Voltage test meter
3-1 Equipment Needed

Condential 3-2
3-2 Main Procedure
Start
Connect the power
adapter, then turn on
the projector and
input the signal
Does the
projector ignite?
Is image OK?
Is audio OK?
Not fault found
END
A.Power
troubleshooting
B.Image
performance
troubleshooting
C.Audio
troubleshooting
YSE
YES
YES
NO
NO
NO

Condential 3-3
3-3 Power Troubleshooting
Power
troubleshooting
Does projector
ignite?
No fault found
END
The power source is
battery.
Whether the battery
connects to the
projector properly?
Connect the battery
properly.
Take off the battery and
check whether the
connectors are sag or
broken.
Clean the
connectors of the
battery and install it
after 5s.
Does projector
ignite?
Whether the
capacity of the
battery is
enough
Change main board.
Change battery.
Does the engine
module securely
connect with the main
board?
Change main board. Does projector
ignite?
Change engine
module.
The power source is
adapter.
Whether the USB cable
and power adapter
securely connect with
the projector?
Does projector
ignite?
Properly connect
power adapter and
USB cable.
Does projector
ignite?
Whether the projectorಬs
accessory kit part is
USB cable?
Does projector
ignite?
Use the accessory
kit parts
Does projector
ignite?
Does the power
source provide
AC voltage?
Supply AC
voltage.(110V-
240V)
YES
NO
YES
YES
NO
NO
NO
YES
NO
NO
YES
Connect them
properly.
NO
YES
NO
NO YES
YES
NO YES
NO
YES
NO
NO
NO
YES
YES
YES
Does fan
rotate? YES
YES
Change fan.NO

Condential 3-4
3-4 Image Performance Troubleshooting
Image performance
troubleshooting
Does the optoma
logo show on the
screen?
Have bright dots
on the screen or
white screen?
Change engine
module.
YES
NO
NO
Does the image
show on the
screen?
Ensure signal cable
and signal source
work well.
Does the image
show on the
screen? Change main board.
Does the image
show on the
screen?
Change engine
module.
YES
NO NO
NO
YES
Is focus OK? Make sure the projection distance
is in spec.
Is the projection
lens clean? Change engine module.
Use the soft cloth to
clean the lens.
YES
NO
Is color OK? Ensure signal cable and signal source
work well.
Is focus OK? NO YES
NO
YES
Is color OK? Change main board. Is color OK?
Change engine
module.
YES
NO NO
NO
YES
YES
YES
Have line bar? Make sure the main board and engine module are
assembled properly Have line bar? Change engine
module. Have line bar?
Change main board.
YES YES
YES
NO
Is uniformity
OK?
NO
Make sure the
projection lens and
screen clean.
Is uniformity
OK? Change engine module.
YES
NONO
NO
No fault found.
END
YES
YES
Change main board.

Condential 3-5
3-5 Audio Troubleshooting
Audio
troubleshooting
Plug in signal cable
and play audio
signal
Have audio
sound output
from the internal
speaker?
Does the signal
and source work
well?
Ensure the signal
and source work
well
Not fault found.
Change main board.
END
NO
YES
NO
If the sound is
abnormal?
NO
YES
Change main board.YES

Condential 4-1
Chapter 4
Function Test&Alignment Procedure
PK-301/PK320/PK301 PLUS
4-1 Test Equipment Needed
- DVD player with Multi-system (NTSC/PAL)
- Equipped "Component", "S-Video" , "Composite"
- Minolta CL-100
- Quantum Data 802B or CHROMA2327 (Color Video Signal & Pattern Generator)
- Remote control
- PK301 24P to VGA-M (P/N: 42.0020AG001)
- Mini JACK-M to 3*RCA-F R/W/Y cable (P/N: 42.00237G001)
4-2 Service Mode
1. Turn on the projector
2. Do the following actions sequentially to get into service mode
- Press "Left Left -> Right Right -> Down Down -> Up Up" (For PK-301/PK301 PLUS)
- Press"Menu","Up","Left","Down","Right","Up","Left","Down","Right" (For PK320)
- Service mode will be shown
- After conrming the conguration, choose "menu" to exit.
4-3 System Reset
After nal QC step,we have to erase all saved change. The following actions will allow you
to erase all end-users’ settings and restore the default setting:
- Get into service mode.
- Press “right“ and then choose “system reset“ at the bottom of the menu

Condential 4-2
PK-301/PK320/PK301 PLUS
4-4 Test Condition
4-4-1 Normal Test Condition
- Circumstance brightness: Dark room less than 2.0 lux
- Screen size: 20 inches
Screen Defects
Defect specication table
Order Symptom Pattern Criteria
1Dark pixel (dots) White pattern A≤4
2Unstable pixel (dots) Any pattern A=0
3Adjacent pixel (dots) Any pattern A=0
4Bright pixel (dots) Gray 10 pattern A=0
5Bright dot on frame Gray 10 pattern ≤1
< Figure:Figure: Zone A(as green line) Denition>